Sound deadening and heat insulating material and method of making the same



Aug. 4.. 1931. H. B. LINDSAY ET AL 1,317,036

SOUND DEADENING AND HEAT INSULATING MATERIAL AND METHOD OF MAKING THE SAME Flled March 11, 1929 i i Q i I E Patented Aug. 4, 1 931.

- UNITED STATES- PATENT- OFFICE HARVEY 1B. LINDSAY, OI EVANSTON, AN D ARTHUR L. (ELEMENTS, OF CHICAGO, ILLINOIS, ASSIGNORS TO DRY-ZERO CORPORATION, OF WILMINGTON, DELAWARE, A COR rona'rron or nmwann sormn nnannume' m mm msunn'rme narmmr. am) umnon or MAKING THE SAME Appllcation med larch 11, 1929. Serial 1%. 348,008.

The invention relates to sound deadening and/or heat insulating material and. a method of making the same.

Heretofore, where ceiba fibres, generally called kapok, have been used for sound (leadening or heat insulating purposes the only way of forming them into a product that could be handled readily was to enclose a bat of such fibres within an outer covering in the form of a blanket in which the covering was stitched to the bat. Such a product and the method of making the same is described in United States Letters Patent No. 1,679,251, dated July 31, 1928, and No. 1,584,386, dated May 11, 1926. While it is not broadly new to attach coverings to fibrous material, in the 1 present instance the usual practice of merely coating the material with adhesive could not be followed owing tothe resistance of ceiba fibres to moisture penetration. The attachment of the covering to the bathas, however, been accomplished in the present instance by subjecting the bat, while immersed in the sizing, to pressure and then allowing it to expand while still submerged, thereby causing a suction effect, which sufficiently coats the surface of the bat adjacent the covering to enablethe same to adhere thereto. Furthermore, according to the present inventionthe hat of ceiba fibres, such as kapok, is formed with the fibres extending from end to end in generally the same direction, thereby pro ducing a layer of fibrous material having a definite am to which bat reinforcing layers of fa ric, preferably muslin, are secured by the method hereinafter described.

The invention further consists in the several' features hereinafter more particularly described and pointed out in the claims at the conclusion hereof.

In the drawings Fig. 1 is a vertical sectional view through an apparatus used in carrying out the method embodying the invent1on..

Fig. 2 is a perspective view of a block of the new sound deadening and insulating material. I Referring to thedrawings and also having reference to the prior patents above noted, the bat 4 of ceiba fibres, with the greater portion thereof arranged to extend from end to end v in same direction of the bat, is moved through.

the channelplates' 5 and thence through a former, including top and bottom plates 6 provided with air release openings 7, between j top and bottom coverings 8', preferably of a strong fabric, such as muslin. I

'-Passing out of the formers the bat and its covering are pulled down under a heavy roller 9 into a tank 10 containing a bath 11 of sizing,

-na lled in the frame of the apparatus and carrylng asprocket 18 connected by a chain 19 to a sprocket 20 on a shaft 21. An arm 22 associated with the shaft 21 has a weight 23 adjustably mounted thereon which acts to partially counter-balance the weight of the roller 9. By adjusting the weight 23 relative to the arm 22 the pressure on the bat can be-varied to suit the required pressure for the thickness of the bat being run.

By means of the roller 9 the light fibres of the at which are potentiallyadverse'to taking on moisture are forced down below the surface of the sizing bathand the pressure exerted by theroller squeezes out the air natu'rally in it and as the pressure is released and the batexpands a suction is set up so that a certain amount of the sizin is drawn in and surrounds the fibres imme iately in contact with the outer coverings and causes them tb adhere to said coverings.

Passing out of the bath the covered bat is drawn between the doctors or scrapers 12 and 1 13, one of which may be mounted for suitable ad ustment to the different thiclmesses of material, which scrape off the surplus sizing or silicate of soda and at the same time force the outer fibres into closer contact with the coverings, cementing themtogether. In

practice the sizing 24 provides a la er of cemented fibres and fabric about one-thirty-secnd of an inch thick and when the material thus formed is dried it may be readily cut into the desired form and will retain its block or slablike formation, as shown in Fi 2, wherein it is noted that the majority o the fibres 25 forming the bat extend from end to end in one direction of the layer.

While the silicate of soda serves to stiffen the coverings, said coverings are still in a 10 sufiiciently pliable condition so that they may be readily worked and so that they will operate efiiciently in service.

lVhat we claim as our invention is: 1. As a new article of manufacture, ma-

- terial of the character described comprising a hat of non-absorptive fibres consisting principally of ceiba fibres, the majority of which extend from end to end generally in the same direction, and a fabric covering for said bat impregnated with silicate of soda which also coats the bat to form an adhesive securing said covering to the bat, the bat itself not being penetrated by said adhesive.

2. As a new article of manufacture, material of the character described comprising a hat of ceiba fibres having an endwise disposed formation, fabric coverings for said bat, and sizing impregnating said coverings to stiffen the same and form an adhesive coating between the bat and said coverings, the bat itself not being penetrated by said adhesive. 3. That step in the method of forming a sound deadening and insulating material which consists in immersing a bat containing ceiba fibres in a bath of sizing between outer coverings of impregnable material and forcing air out of said bat and subsequently allowing said bat to expand while immersed to enable said fibres to take on said sizing adja- 40 cent said coverings whereby said bat receives an adhesive coating for securing said coverings to it. v

4. The method of forming a sound deadening and insulating material which consists in immersing a bat containing ceiba fibres in a bath of sizing between outer coverings of impregnable material and forcing air out of said bat and subsequently allowing said bat to expand while immersed to enable said fibres to take on said sizing adjacent said coverings, scraping off the excess sizin and forcing the fibres into closer contactwit h said coverings, then drying the treated material.

In testimony whereof, we aflix our signatures.

HARVEY B. LINDSAY. ARTHUR L. CLEMENTS. 

